INSTALLATION DATA
712 SerieS Pilot
ignition SyStemS
(FlAme reCtiFiCAtion)
712-022
CSA DESIGN CERTIFIED TO APPLICABLE A.N.S.I. STANDARD
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ORDERING DATA
ORDER NUMBER
GAS VALVE
CONNECTION
IGNITION UNIT MODEL - GAS DESCRIPTION
712-005
722-079
1/2" x 1/2"
780-845
(Lockout)
Universal Model- Gas valve has natural gas pressure
regulator set at 3.5" WC. A separate LP gas pressure
regulator set at 11.0" WC is also included. 170,000 BTU
Max. Nat. Gas/272,000 BTU Max. LP gas.
712-006
700-056
3/4" x 3/4"
780-845
(Lockout)
Universal Model - Gas valve has natural gas pressure
regulator set at 3.5" WC. A separate LP gas pressure
regulator set at 11.0" WC is also included. 350,000 BTU
Max. Nat. Gas/560,000 BTU Max. LP gas.
712-008
720-070
1/2" x 3/4"
780-845
(Lockout)
Universal Model - Gas valve has natural gas pressure
regulator set at 3.5" WC. A separate LP gas pressure
regulator set at 11.0" WC is also included. 200,000 BTU
Max. Nat. Gas/320,000 BTU Max. LP gas.
712-009
700-059
1" x 1"
780-845
(Lockout)
Universal Model - Gas valve has natural gas pressure
regulator set at 4.0" WC. A separate LP gas pressure
regulator set at 11.0" WC is also included. 720,000 BTU
Max. Nat. Gas/1,152,000 BTU Max. LP gas.
Non-lockout Models - Caution: Do Not Use On LP Gas Applications
712-015
720-072
1/2" x 3/4"
780-715
(Non-lockout)
Natural Gas Only - Non-lockout. Valve has 1/2" side outlets.
Pressure regulator is factory-set at 3.5" WC 200,000 BTU
Max.
712-016
700-056
3/4" x 3/4"
780-715
(Non-lockout)
Natural Gas Only - Non-lockout. Pressure regulator is
factory-set at 3.5" WC 350,000 BTU Max.
712-017
720-070
1/2" x 3/4"
780-715
(Non-lockout)
Natural Gas Only - Non-lockout. Pressure regulator is
factory-set at 3.5" WC 200,000 BTU Max.
712-019
700-059
1" x 1"
780-715
(Non-lockout)
Natural Gas Only - Non-lockout. Pressure regulator is
factory-set at 4.0" WC 720,000 BTU Max.
712-022
722-079
1/2" x 1/2"
780-715
(Non-lockout)
Natural Gas Only - Non-lockout. Pressure regulator is
factory-set at 3.5" WC 170,000 BTU Max.
*The 780-845 lockout ignition control used in the 712 series Kits, provides 90 seconds of spark followed by a six minute
time delay (purge) period between ignition attempts. After three tries, if no pilot ame is sensed, 780-845 goes into a 1 hour
lockout period. At the end of the 1-hour lockout period, if the demand for heat is still present, unit repeats the three tries for
ignition.
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SPECIFICATIONS
GAS VALVES
The Robertshaw
®
gas valves used in the 712 Series kits are CSA design certified to applicable ANSI standards. Gas valves
that are included in the 712 Series pilot ignition systems have a built-in, slow-opening feature for soft ignition characteristics
at the main burner. Does not include the 712-005 and 712-022 kits.
Electrical 24 volt, 60 Hz
Ambient rating - 40°F to 175°F
(- 40°C to 80°C)
Capacity (maximum regulation)
1/2" x 3/4" straight-through 300,000 BTU
3/4" x 3/4" straight-through 350,000 BTU
Pressure regulator (factory-set) 3.5" WC Natural Gas
(Adjustable 3" to 7" WC)
Electrical 24 volt, 60 Hz
Ambient rating - 40°F to 175°F
(- 40°C to 80°C)
Capacity (maximum regulation)
1" x 1" 720,000 BTU
3/4" x 1" using reducer bushings
(included)
530,000 BTU
3/4" x 3/4" using reducer bushings
(included)
450,000 BTU
Pressure regulator (factory-set) 4.0" WC Natural Gas
(Adjustable 3" to 7" WC)
Electrical 24 volt, 60 Hz
Ambient rating - 40°F to 175°F
(- 40°C to 80°C)
Capacity (maximum regulation)
1/2" x 3/4" straight-through 200,000 BTU
Pressure regulator (factory-set) 3.5" WC Natural Gas
(Adjustable 3" to 7" WC)
11.0" WC LP Gas (Adjustable 8"
to 12" WC)
Electrical 24 volt, 60 Hz
Ambient rating - 40°F to 175°F
(- 40°C to 80°C)
Capacity (maximum regulation)
1/2" x 1/2" straight-through 170,000 BTU
Pressure regulator (factory-set) 3.5" WC Natural Gas
Input voltage 24 VAC 50/60 Hz
Transformer 24 VAC / 20 VA minimum
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IGNITION CONTROL UNITS
Robertshaw ignition control units used in the 712 Series kits are CSA design certified to applicable ANSI standards.
Safety lockout timing (780-845) See footnote*
Spark rate 3 to 4 sparks per second
Relay contact ratings
Pilot valve 1 amp at .5 PF
Main valve 1 amp at .5 PF
Combined load 1.5 at .4 PF
Flame sense current .7 µA DC @ 25°C / 24 VAC
Maximum total current load 1.5 amp
Flame failure re-ignition time .8 seconds maximum
Thermostat anticipator setting .7 amp
Ambient rating - 40°F to 175°F
(- 40°C to 80°C)
Relative humidity 95% non-condensing at 104°F
*The 780-845 lockout ignition control used in the 712 series kits, provides 90 seconds of spark followed by a six minute time
delay (purge) period between ignition attempts. After three tries, if no pilot ame is sensed, the 780-845 goes into a 1 hour
lockout period. At the end of the 1 hour lockout period, if the demand for heat is still present, the unit repeats the three tries
for ignition.
PRE-INSTALLATION INSTRUCTIONS
780-715
780-845
CAUTION
The 712 Series Pilot Ignition System must be installed
by a qualified installing agency with due regard for
safety. Improper installation could result in a hazardous
condition.
Installation must comply with all local codes. In the
absence of local codes, the latest edition of the National
Fuel Gas Code, ANSI Z223, and the National Electrical
Code ANSl/NFPA No. 70 must be used.
The 712 Series Pilot Ignition System has been designed
for an easy installation, however, for the system to
function properly and to give trouble-free service. The
installer must follow these installation instructions word
for word and without taking any short cuts. Take your
time installing this system, make sure it is working
properly before leaving the job site. Failure to do so could
result in a system failure.
This Pilot Ignition System must be used only on
appliances equipped with an atmospheric gas burner.
Use on direct-vent type appliances and power burners is
prohibited.
Be sure you have the correct Pilot Ignition System for the
type of gas used on the application, LP or natural. Using
an incorrect system could result in a hazardous condition.
LP Gas Application
Use the lockout models only for inside or poorly
ventilated applications.
Natural Gas Application
Use either model type: Lockout models 712-005, 712-006,
712-008, 712-009 or non-lockout models 712-015, 712-016,
712-017, 712-019, 712-022.
Ambient Temperature Limitations
Be sure the installation of the Pilot Ignition System will
not exceed its rated ambient temperature range: -40°F to
175°F (-40°C to 80°C). This is extremely important when the
application is being made to a rooftop unit in cold climates.
SAFETY INSPECTION PROCEDURES
The CSA pre-installation safety procedures listed below are
intended as a guide to aid in determining that an appliance is
properly installed and is in a safe condition for continued use.
This procedure is predicated on central furnace and boiler
installations equipped with an atmospheric gas burner(s)
and not at the direct-vent type. It should be recognized that
generalized test procedures cannot anticipate all situations.
Accordingly, in some cases, deviation from this procedure
may be necessary to determine safe operation of the
equipment.
A. This procedure should be performed prior to any
attempt at modification of the appliance or
the installation.
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B. If it is determined there is a condition which could
result in unsafe operation, the appliance should be
shut off and the owner advised of the
unsafe condition.
The following steps should be followed in making the safety
inspection:
1. Conduct a gas leakage test of the appliance piping and
control system downstream of the shutoff valve in the
supply line to the appliance.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine that there is no blockage
or restrictions, leakage or corrosion or other deficiencies
which could cause an unsafe condition.
3. All gas equipment must have an accessible manual gas
shutoff valve installed in the gas supply line upstream of
the appliance. If a manual, accessible gas valve is not in
the gas supply line within six feet of the appliance, one
shall be installed. Shut off all gas to the appliance and
shut off any other fuel burning appliance in the same
room. Use the shutoff valve in the supply line to
each appliance.
4. Inspect burners and crossovers for blockage and
corrosion. Inspect all wiring for damage, correct any
defects found.
5. Applicable only to warm air heating appliances. Inspect
heat exchangers for cracks, openings or
excessive corrosion.
6. Applicable only to boilers. Inspect for evidence of water
or combustion product leaks.
7. As far as is practical, close all building doors and
windows and all doors between the space in which the
appliance is located and other spaces of the building.
Turn on clothes dryers. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers. If after completing
steps 7 through 12, it is believed sufficient combustion
air is not available, refer to 1.3.4 National Fuel Gas Code
(2223.1) for guidance.
8. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
9.
A. Determine that the pilot is burning properly and that
main burner ignition is satisfactory by interrupting
and re-establishing the electrical supply to the
appliance in any convenient manner.
B. With a manometer, determine manifold pressure in
order to match input after the new control is installed.
10.
A. Visually determine that main burner gas is burning
properly; i.e., no floating, lifting or flashback. Adjust
the primary air shutter(s) as required.
B. If appliance is equipped with high and low flame
control or flame modulation, check for proper main
burner operation at low flame.
11. Test for spillage at the draft hood relief opening after
5 minutes of main burner operations. Use a draft
gauge, the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
12. Return doors, windows, exhaust fans, fireplace dampers
and all other fuel-burning appliances to their previous
conditions of use.
13. Applicable only to warm air heating appliances: Check
both limit control and fan control for proper operation.
Limit control operation can be checked by temporarily
disconnecting the electrical supply to the blower motor
and determining that the limit control acts to shut off the
main burner gas.
14. Applicable only to boilers:
A. Determine that the circulating water pumps are in
operating condition.
B. Test low water cutoffs, automatic feed water
controls, pressure and temperature limit controls and
relief valves in accordance with the manufacturer's
recommendations and instructions to determine that
they are in good operating condition.
TESTING THE EXISTING SYSTEM
Before starting installation, a safety inspection of the
appliance must be performed. Once safety inspection has
been completed, continue as follows:
1. Check that the existing pilot is a thermocouple type used
with an electromagnetic safety. Some manufacturers
use bimetal type pilots wired to the valve operator. If the
application has a bimetal pilot, it must be replaced with a
thermocouple-type pilot.
2. The Pilot Ignition System is designed to be adapted to
the existing pilot.
NOTE: Robertshaw and CSA recommend that the original
pilot be used and remain in its original position.
3. Locate the rating plate on the appliance and determine
the input rating (BTU per hour). The input rating
(capacity) for the Pilot Ignition System must be equal
to or greater than the input rating of the appliance. See
SPECIFICATIONS for Pilot Ignition System Capacity or
Input Rating.
4. Do not install in a wet area without protection for
the components.
5. To ensure proper operation, the appliance transformer
must be rated at:
24 volts/20VA (minimum)
24 volts/40VA (minimum) - When used in conjunction
with an Automatic Vent Damper.
The output of the appliances transformer can be
determined by the following steps:
A. Compute the total current draw by adding the
current draw of the Pilot Ignition System (.7 amp) to
the current draw of any associated valving, relays,
dampers or other devices operated by
the transformer.
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B. Multiply the total current draw computed in "A" above
by 24 volts. This will give the total VA (Voltage-
Amperage) required.
C. The total VA (Volt-Amperage) required should be
equal to or less than the VA rating of the
appliance transformer.
D. If the total VA (Volt-Amperage) required is greater
than the VA rating of the transformer, replace it with
a Class 2 transformer of adequate rating.
6. Cycle the furnace ON to ensure it is working properly. If
the transformer, limit switch or thermostat are faulty, the
ignition system will not function. Check the performance
characteristics of the pilot flame. The flame should be
impinging on the thermocouple and be blue in color. If
not, you will need to adjust the pilot and/or clean the
orifice and pilot tube. Be sure that inlet gas pressure
is adequate.
7. Turn OFF all electrical power and gas to the appliance
before attempting to disconnect the wiring and gas valve.
To shut off the gas, use the shutoff valve in the supply
line to the appliance. If a manual gas valve is not in the
gas supply line within 6 feet of the appliance, and in an
accessible location, one shall be installed. DO NOT USE
THE GAS COCK ON THE GAS VALVE.
8. Remove the thermocouple and pilot tubing from the
existing gas valve.
9. You may encounter two methods of gas valve wiring.
Determine from the diagrams below which one you have.
Disconnect the electrical leads from the gas valve.
A. TWO TERMINAL CONNECTION
Disconnect the two wires connecting the gas valve.
B. THREE TERMINAL CONNECTION
If three terminals on the gas valve are used, two
wires may be connected to a common terminal.
Remove these two wires first and wire-nut them
together. Three wire nuts are provided in the kit.
Now, remove the other two wires from the existing
gas valve.
10. Remove gas valve and/or controls containing the main
valve, regulator and safety functions from the manifold.
These functions are built into the new replacement
gas valve.
11. Remove the pilot assembly and disconnect the
thermocouple from the pilot. The pilot will be reinstalled
back into its original mounting position.
12. Inspect the inside of the pilot tubing. It should be free
of any scale or other foreign matter. Clean or replace if
necessary. We also recommend that the pilot orifice be
cleaned to ensure optimum system operation.
INSTALLATION INSTRUCTIONS
IGNITOR/SENSOR ASSEMBLY
NOTE: On some pilot applications a special adaptor kit is
required. These adaptor kits are shown on page
8. Order these pilot adaptor kits separately
if needed.
1. Assemble the combination ignitor/sensor assembly by
sliding the mounting bolt through the mounting bracket
as shown in Figure 1.
Figure 1
2. The ignitor/sensor assembly is ready to be attached to
the furnace pilot. Slide the mounting bolt with the ignitor/
sensor bracket down through the thermocouple opening
of the pilot frame as shown in Figure 2. Install the
retainer nut onto the mounting bolt and tighten
finger tight.
Figure 2
3. The ignitor/sensor can now be positioned for proper
sparking and sensing. To obtain the best ignition
characteristics:
• The ignitor/sensor tip should be located on a
horizontal plane with the top of the pilot gas exit port.
• The tip should be located 1/8" (recommended spark
gap) from the edge of the pilot hood.
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Figure 6
B. Measure down the ignitor/sensor rod this distance
plus 1/16" to allow for bend radius Figure 7. DO
NOT BEND YET.
Ceramic Insulator
Figure 7
7. Holding pliers firmly on the ignitor/sensor rod at the
distance measured, use finger pressure on the ignitor/
sensor rod tip to slowly bend it towards pilot hood,
Figure 8. If tip is too long, cut off excess.
Figure 8
NOTE: lgnitor/sensor tip must be in pilot flame for the Ignition
Control Unit to function properly.
8. Reinstall pilot assembly back into its original mounting
position.
• Be sure that sparking will occur in the path of the
gas flow.
• Excess "wire or rod" should be cut off.
• Tighten the mounting bolt firmly so that the bracket
assembly will not move or change position once the
pilot is installed. See Figure 3.
Figure 3
4. Bend the tabs to the ignitor/sensor mounting bracket
down and around the pilot bracket frame. Using a pair of
pliers, crimp the tabs so they grip the pilot bracket. This
will hold the electrode assembly firmly in place as shown
in Figure 4.
Figure 4
5. When selecting the ignitor/sensor tip location, remember
the spark will jump the narrowest gap available to the
nearest ground metal. Ensure that this gap is always at
the point you select and not to the main burner, furnace
chassis, burner manifold, or a part of the pilot hood
where there is no flow, see Figure 5. The tip must be in
the pilot flame for the ignitor/sensor to function properly.
Bend Tabs Down
Figure 5
6. After crimping the ignitor/sensor mounting bracket tabs
and selecting the point for the ignitor/sensor tip to spark to:
A. Measure the distance from this point to the ignitor/
sensor rod Figure 6.
CAUTION
Always hold the ignitor/sensor rod between the
ceramic and the bend you are making. This will
must not contact the ceramic portion of the ignitor/
sensor assembly.
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NOTE: Pilot is not to be relocated or altered. If replacing the
pilot becomes necessary due to wear or damage, an
exact replacement must be used.
SPECIAL PILOT ADAPTOR KITS
These special pilot adaptor kits are NOT included in the 712
kits. They must be ordered separately.
PILOT ADAPTOR KIT
Includes all the necessary parts to
adapt the Magic Chef, Gaffers & Sattler
sheet metal pilot to the 712 Series
flame rectification pilot system.
ORDER 1751-712
INSTALLING THE GAS VALVE
• Installation and servicing of gas appliances and
ignition systems must only be performed by
qualified personnel.
• Turn off gas and electricity before starting installation
or service.
• When replacing an LP control or a natural gas
control, the new control must have the same
regulator setting as the old control, or as specified
on the appliance rating plate.
• To install or remove the control, use the inlet boss as
a gripping location to prevent unwanted rotation. Do
not grip body with pipe wrench or vise.
• Make sure gas piping is pressure tested before
control is connected. High pressure can damage the
control causing a hazardous condition.
• Make sure piping is clean and free from burrs.
Apply a small amount of good quality pipe thread
compound or plumbers tape suitable for the gas
being used. Thread compound should be used
sparingly on male threads only, leaving the first two
threads clean.
1. Install the gas valve so gas flow conforms with the inlet
gas flow indicated on the valve body. A wrench should
only be used on flat surfaces of the inlet boss. Never use
a wrench on the body of the valve as this may distort
the casting.
2. A sediment trap must be present in the gas supply line.
If one is not present one must be installed to prevent dirt
from entering the control. See Figure 9. All piping must
conform to local codes and ordinances and with National
Gas Codes (ANSI Z223.1 and NFPA No. 54).
Figure 9
3. The valve should be mounted with the wiring terminals
at the top for easy access in installation of wiring and
fixture service testing.
WARNING: Do not mount valves upside down.
4. Connect the pilot tubing to the pilot gas outlet. Use the
fitting provided and tighten for gas seal. Do not bend the
tubing after tightening.
NOTE: Valves have a built-in vent limiter. The regulator vent
is tapped so a tubing adaptor can be installed if vent
tubing is required by local codes.
All components must be securely mounted with screws, bolts
etc., within the appliance.
WIRING THE IGNITION CONTROL UNIT
1. Wiring must conform to local codes and ordinances. A
high limit switch is required in either the 120V or 24V
side of the transformer.
2. Make certain all wiring connections are tight.
3. The 712 series pilot ignition kits include a six-wire (blue)
harness assembly. This harness assembly connects the
gas valve to the ignition control unit. To wire the ignition
control unit:
A. Attach blue wire to terminal "PV" (pilot valve,
pilot gas).
B. Attach red wire to terminal "MV" (main valve,
main burner).
C. Attach gray wire to terminal "TH" (thermostat).
D. Attach green wire to "GND" terminal.
E. Attach black/white wire to terminal
"MV/PV" (common).
NOTE: The white and black wires are assembled into one
quick-connect terminal and it is normally attached to
the MV/PV terminal. However, the GND, MV/PV and
TR terminals are electrically identical, and the green,
white and black wires may be attached to any of
these terminals.
4. If the appliance has an automatic vent damper, verify
that damper is in the full open position. We recommend
that the 712 series kit be installed and tested as
instructed in SYSTEM CHECKOUT PROCEDURES prior
to connecting the vent damper into the system.
5. Locate ground terminal connector.
WARNING: Gas valve must be grounded to prevent
burnout of gas valve terminal circuit board.
A. The 7000 Series Gas Valve is included in the
following kits: 712-006, -009, -016 and -019. Attach
ground terminal connector to the top of the
gas valve.
CAUTION
clogging of the tubing and improper regulator operation. If
shielded from moisture.
may clog and cause gas valve to malfunction.
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B. The 7200 Series Gas Valve is included in the
following kits: 712-008 ,-015 and -017. Attach the
grounding terminal to the gas valve.
C. The 2000 Series Gas Valve is included in the
following kits: 712-005 and 712-022. Attach the green
ground wire in the wiring harness to the terminal on
the gas valve.
Grounding Terminal
Figure 10
6. Locate the green wire in the six-wire harness. Be sure
that this wire is connected to the GND terminal on the
ignition unit and to the gas valve - see page 10.
7. Locate the separate ground wire included in the 712 kit.
Connect the "ring" terminal to the mounting screw that
attaches the pilot assembly to the furnace. Connect the
other end to the "TR" terminal on the ignition control unit.
8. The six-wire harness is used to connect the ignition
control unit to the gas valve and to the thermostat control
circuit. Determine which gas valve type you have (7000,
7200 or 2000) and proceed as directed by the
following instructions.
9. Some appliance wiring may result in one terminal of the
secondary side of the transformer being grounded. If this
condition exists, damage to the transformer may occur if
the two wires (black and gray) in the wiring harness are
connected improperly to the two wires removed from the
old gas valve. It is necessary to determine which wire is
grounded before proper connection to the wiring harness
can be made.
A. Be sure all gas to the appliance is turned off. Make
sure the two wires removed from the old gas valve
will not touch the furnace chassis or each other.
B. Turn on the electrical power to the furnace and set
the thermostat to the high setting.
C. Set the test meter to the 24 volt AC scale. Touch or
clamp one meter probe to the chassis of the furnace.
D. Touch the other probe of the meter to each wire, one
at a time.
E. If no meter reading is obtained, the two wires
removed from the old gas valve may be connected
to either wire (black or gray) in the new wiring
harness.
If a 24 volt reading is obtained at one wire, that wire
must be connected to the gray wire in the wiring
harness.
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7000 SERIES GAS VALVES
When installing kit numbers 712-006, -009, -016, and -019,
refer to the wiring diagrams shown below. This illustrates
the wiring method when using a 7000 series gas valve. The
wiring connections at the gas valve are as follows:
1. Locate the 4" white jumper wire in the kit.
2. Attach one end (quick-connect) to one terminal of
the solenoid valve. Attach the other end to the screw
terminal "TR" on the gas valve operator.
3. Connect the white wire in the wiring harness to the quick
connect terminal at "TR".
4. Connect the red wire to the "TH" terminal on the gas
valve.
5. Attach the blue wire which has a non-insulated
connector to the solenoid pilot valve.
6. Attach green wire to the ground terminal on the gas
valve.
7. Connect the wire from the pilot ignitor/sensor to the
"IGN" terminal on the ignition control unit.
8. With all wiring completed to this point, return to step 9
in the WIRING THE IGNITION CONTROL UNIT section
and proceed as directed.
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7200 SERIES GAS VALVES
When installing kit numbers 712-008, 712-015, and 712-017,
refer to the diagrams shown below. This illustrates the wiring
method when using a 7200 series gas valve. The wiring
connections at the gas valve are as follows:
1. Attach the blue wire which has a non-insulated
connector to terminal "P" on the gas valve connector.
2. Attach the white wire to terminal "C".
3. Attach the red wire to terminal "M".
4. Attach green wire to the ground terminal.
5. Connect the wire from the pilot ignitor/sensor to the
"IGN" terminal on the ignition control unit.
6. With all wiring completed to this point, return to step 9
in the WIRING THE IGNITION CONTROL UNIT section
and proceed as directed.
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2000 SERIES GAS VALVES
When installing kit numbers 712-005 and 712-022, refer
to the diagrams shown below. This illustrates the wiring
method when using a 2000 series gas valve. The gas valve
connections are made by a plug-in terminal.
1. Attach green wire to ground terminal.
2. Connect the wire from the pilot ignitor/sensor to the
"IGN" terminal on the ignition control unit.
3. With all wiring completed to this point, return to step 9
in the WIRING THE IGNITION CONTROL UNIT section
and proceed as directed.
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SYSTEM CHECKOUT
PROCEDURES
The initial installation portion is now completed. The
checkout procedures listed below must be followed. While
there are redundant safety features built into the system, it is
imperative that you follow the steps outlined below to ensure
proper and safe operation. If you encounter any irregularities,
refer to the TROUBLESHOOTING GUIDE.
1. Check all wiring connections.
2. Turn on main gas supply and put the manual valve or
selector arm on the gas valve into the "ON" position.
3. Use a leak test solution to check piping for gas leaks.
Repair if needed.
4. Turn on electrical power.
5. Set thermostat to high.
WARNING: Vent damper must be in the fully open
position before the ignition system is
energized. Failure to verify this may cause a
serious health hazard to occupants.
6. Sparking begins, pilot gas ignites.
7. Pilot flame on ignitor/sensor, main burner on.
8. If the ignition control unit is a 780-715, with main burner
on, cycle thermostat off then on. System will turn off and
immediately on again.
9. With the main burner on, turn the manual gas valve to
off position. Wait until all flame is out. Turn manual gas
valve on again.
A. Sparking will begin as soon as the pilot flame is out.
B. Pilot ignition takes place when gas flow is restored.
10.
With the main burner on, turn the manual gas valve
off. Sparking will begin when the pilot flame goes out.
After 90 seconds the system will go into time delay (6
minutes) and sparking will cease. The lockout ignition
control used provides 90 seconds of spark followed by
a six minute time delay (purge) period between ignition
attempts. After three tries, if no pilot flame is sensed, a
1-hour lockout period will begin. At the end of the 1-hour
lockout period, if the demand for heat is still present, unit
repeats the three tries for ignition.
11. Check manifold pressure and compare the reading with
those obtained in the PRE-INSTALLATION - SAFETY
INSPECTION PROCEDURES. Adjust pressure regulator
(if necessary) to match the original input.
12. Visually determine that the main burner is burning
properly, as it was during the PRE-INSTALLATION -
SAFETY INSPECTION PROCEDURES; i.e., no floating,
lifting, or flashback. Adjust the primary air shutter(s)
as required.
13. It is absolutely necessary that the system be cycled
normally (thermostatically controlled) through at least
three complete heating cycles. Set thermostat to a
temperature slightly higher (at least 5°) than the existing
ambient. Allow the appliance to cycle ON and run
through a normal cycle. Do not manually shorten
the cycle.
14. Applicable only to furnaces: Check both the limit
control and the fan control for proper operation. Limit
control operation can be checked by blocking the
circulating air inlet or temporarily disconnecting the
electrical supply to blower motor. Determine that the limit
control acts to shut off the main burner gas.
Applicable only to boilers: Determine that the circulating
water pumps are in operating condition. Test low
water cutoffs, automatic feed controls, pressure
and temperature limit controls, and relief valves in
accordance with the manufacturer's recommendation to
determine they are in operating condition.
15. The initial checkout procedures have been completed.
If the system has functioned normally, return thermostat
setting to its normal setting. The qualified installing
agency must completely fill out and apply the yellow
appliance conversion sticker to the front of the appliance.
Leave these and all other instructions with
the homeowner.
Robertshaw 1-963 Rev D.indd 13 11/3/14 3:33 PM
14
TROUBLESHOOTING GUIDE
PILOT IGNITION SYSTEM / FLAME
RECTIFICATION / IGNITION CONTROL
There are five potential problem conditions with the
thermostat set high.
To perform the following test you will need a volt /ohmmeter.
Refer to your appropriate wiring diagrams.
The ignition control can also be tested, using the Robertshaw
ignition control tester, part number 900-575.
gas.
Possible Causes:
A. No main power
B. Faulty transformer
C. Faulty thermostat
D. Faulty limit
E. Faulty ignition control unit
Solution:
1. With power on and thermostat set high, set your test
meter to the 24 volt scale. Probe terminals TH and TR. If
you do not read 24 volts, the problem is not the ignition
system. Perform normal system checks of main power,
transformer, thermostat and the limit control. If you do
read 24 volts at TH and TR the problem is in the ignition
system. Check for loose or defective wiring. If wiring is
good replace the ignition control unit.
Possible Causes:
A. Main gas supply turned off
B. Manual valve on gas valve turned off
C. Faulty primary valve in the gas valve
D. Faulty wire connection
E. Faulty ignition control unit
Solution: Set test meter to 24 volt scale.
1. Be sure main gas valve (gas cock or selector arm) is
turned on.
2. With gas on and the system sparking, probe terminals
PV and TR. If 24 volts is read at these terminals and
pilot gas does not flow, replace the gas valve.
3. If you do not read 24 volts at terminals PV and
MV/PV replace the ignition control unit.
Possible Causes:
A. Defective ignitor/sensor and/or its wiring
B. Faulty ignition control unit
Solution: Set test meter to ohm scale.
1. Disconnect the wire from the IGN terminal on the ignition
control unit.
2. Touch one meter probe to the tip of the ignitor/sensor
rod in the pilot. Touch the other probe to the quick-
connect at the other end of the ignitor/sensor wire.
3. If you have continuity from the tip of the
ignitor/sensor rod to the connector and no spark, replace
the ignition control unit.
4. If you do not have continuity through the wire and the
ignitor/sensor, check for loose wire connection in the
wire. Repair as needed.
5. Check to see if spark shorts to furnace through a cut in
the ignitor wire.
not turn on.
Possible Causes:
A. Faulty main valve coil in the gas valve
B. Faulty ignitor/sensor and/or its wiring
C. Ground wire not attached to furnace chassis
D. Flame rectification signal from pilot to ignition control
unit weak
E. Faulty ignition control unit
Solution: Set test meter to 24 volt scale.
1. With pilot flame on ignitor/sensor - probe terminals MV
and MV/PV on the ignition control unit. If you read 24
volts here, but not at the gas valve, there is a loose
wiring connection. Repair or replace as needed.
2. If you do read 24 volts at MV and MV/PV and the pilot
flame is impinging on the ignitor/sensor rod, the problem
may be:
• Faulty ignitor/sensor and/or its wiring
• Faulty ignition control unit
• No flame rectification signal to ignition control unit.
3. Set test meter to the ohm scale. Set thermostat low-
system off.
4. Check continuity through the green ground wire between
the pilot mounting bracket and the ignition control unit.
Repair or replace as needed.
5. Check continuity through the green ground wire between
the gas valve and the ignition control unit. Repair or
replace as needed.
6. Check ignitor/sensor for continuity, through the spark/
sensor rod. Also, check ignitor/sensor ceramic for
cracks. Repair or replace as needed.
7. Reconnect all wires that were disconnected, including
the ignitor/ sensor wire and the ground wire.
8. Set thermostat high. With the pilot burning and the flame
on the ignitor/sensor rod, if the main burner does not
turn on - replace the ignition control unit.
Robertshaw 1-963 Rev D.indd 14 11/3/14 3:33 PM
15
Problem #5: Short-cycling of main burner.
Main burner turns off before the thermostat
Possible Causes:
A. Draft condition pulls pilot flame away from ignitor/
sensor rod
B. Incorrect thermostat anticipator setting
C. Pilot flame gets smaller when main burner
comes on.
D. Faulty limit control
Solution:
1. Check the thermostat anticipator setting. Set to .7 amp.
A lower setting will cause short-cycling.
2. Set thermostat high, with main burner on, observe the
pilot flame impingement on the ignitor/sensor rod.
• If pilot flame is small and draft condition pulls flame
from ignitor/sensor rod the burner will turn off and
then on again.
• Adjust pilot flame higher or clean pilot orifice.
• Bend ignitor/sensor rod closer to pilot flame .
3. If flame impingement on the ignitor/sensor is stable and
the system short-cycles, check the limit switch.
4. Set test meter to 110 volt scale.
• When the system cycles off, probe the switch
terminals of the limit switch.
• If you read 110V or 24V across the switch terminals
the limit switch is open. Replace the limit switch.
5. A pilot flame set too high will also cause burner to short
cycle. Pilot flame lifts over ignitor/sensor.
Robertshaw 1-963 Rev D.indd 15 11/3/14 3:33 PM
Customer Service Telephone 1.800.304.6563
Customer Service Facsimile 1.800.426.0804
Robertshaw
®
, Ranco
®,
Paragon
®
and Uni-Line
®
is a trademark
of Robertshaw its subsidiaries and/or affiliated companies.
All other brands mentioned may be the trademarks of their
respective owners.
For Technical Service
Telephone 1.800.445.8299
Facsimile 1.630.260.7294
www.Uni-Line.com
www.Robertshaw.com
©2014 Robertshaw
10/14 - 1-963 Rev D
Robertshaw 1-963 Rev D.indd 16 11/3/14 3:33 PM
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